Block copolycarbonates containing polylactone blocks and dihydric phenol polycarbonate blocks

ABSTRACT

THIS INVENTION RELATES TO IMPROVED BLOCK COPOLYCARBONATES CONTAINING AN AMORPHOUS, SOFT, RUBBERY SEGMENT OR BLOCK COMPOSED OF LACTONE UNITS AND ANOTHER CRYSTALLINE, HARD, THERMOPLASTIC SEGMENT OR BLOCK COMPOSED OF DIHYDRIC PHENOL CARBONATE UNITS.

United States Patent 3 641 200 BLOCK coPoLYcAimoNATEs CONTAINING POLYLACTONE BLOCKS AND nmvonrc PHENOL POLYCARBONATE BLOCKS Markus Matzner, Edison, N.J., assignor to Union Carbide Corporation, New York, NY. N0 Drawing. Filed Jan. 17, 1969, Ser. No. 792,125 Int. Cl. C08f 45/32; C08g 17/13, 39/10 US. Cl. 260-860 13 Claims ABSTRACT OF THE DISCLOSURE This invention relates to improved block copolycarbonates containing an amorphous, soft, rubbery segment or block composed of lactone units and another crystalline, hard, thermoplastic segment or block composed of dihydric phenol carbonate units.

The present invention also relates to novel liquid compositions formed by extending an appropriate polylactone diol with an extending agent selected from the group consisting of dihydric phenols, aliphatic diols, dicarboxylic acids and hydroxy monocarboxylic acids. The aforementioned extended diols are particularly useful in the production of the block copolycarbonates of this invention.

This invention also contemplates a novel method for reducing the extent of annealing time normally required for the primary crystallization of a block copolycarbonate of this invention comprising including in the block copolycarbonate composition, prior to primary crystallization, a nucleating agent.

Block copolycarbonates of the general class to which the present invention is concerned are well known in the art. There have been a number of patents which have issued in the past few years on block copolycarbonates such, for example, as US. Goldberg Pat. 3,161,615 and UK. Pat. 965,085. Among the many literature references relating to the general subject are Elastomeric Polycarbonate Block Copolymers by E. P. Goldberg, J. Polymer Sci., C4, 707 (1963); Block Copolymers Based on 2,2-(4-Hydroxy Phenyl)-Propane Polycarbonate," part I and part II, appearing respectively in J. Polymer, Sci., 55, 343 (1961) and J. Polymer Sci., A3 2189 (1965).

An object of this invention is to provide an improved block copolycarbonate which has a highly desirable balance of properties, in particular good thermal stability at elevated temperatures.

This invention relates to novel copolycarbonates which are block copolymers. Block copolymers are composed of at least two segments or blocks, at least one segment or block being of one type of unit or group (e.g. lactone units as in the block copolymers of this invention) and at least one other segment or block composed of a diiferent type of units or groups (e.g. dihydric phenol carbonate groups). Block copolymers can have linear, cyclic, branched or cross linked structures.

The block copolycarbonates of this invention comprise (1) divalent carbonate groups, i.e.

(2) divalent polylactone moieties containing a plurality of lactone groups represented by the formula:

wherein R is selected from the class consisting of hydrogen and monovalent hydrocarbon groups free of unsaturation and having 1 to 18 carbon and g is an integer of 5 or 6; and, (3) divalent aromatic carbocyclic residues derived from a dihydric phenol by removal of the hysol 3,641,200 Patented Feb. 8, 1972 -droxyl groups, each of at least some of said carbonate groups being attached to two aromatic carbocyclic residues, and each of at least some of the carbonate groups linking one of said aromatic carbocyclic residues to one of said divalent polylactone moieties, the polylactone moieties being in an amount from about 50 to by weight of the total composition.

Preferred block copolymers of this invention are represented by the formula:

wherein R is a divalent organic radical, preferably a divalent hydrocarbon (e.g. aliphatic) radical or two or more such divalent hydrocarbon radicals joined by ether oxygen; and

wherein R is selected from the class consisting of hydrogen and monovalent hydrocarbon groups free of aliphatic unsaturation and having 1 to 18 carbon atoms and g is an integer of 5 or 6; and,

wherein DH is a'divalent aromatic carbocyclic group derived from a dihydric phenol by removal of the hydroxy groups; and,

wherein x and y have values so that the relative weight of the polylactone blocks are 50 to 80% by weight and the dihydric phenol polycarbonate blocks are 50 to 20% by weight of the total composition; and,

wherein n is in an integer so that the molecular weight of the polylactone segment is in the range of 500 to 3,000; and,

wherein m has a value so that the block copolymer has a reduced viscosity of at least 0.70 in chloroform (0.2 gram block copolymer/ ml.) solution at 25 C.; and,

wherein the block copolycarbonate has a glass transition temperature below 0 C. (preferably below 10 C.) and a tensile modulus of 100 p.s.i. at a temperature of C. (preferably 200 C.), said tensile modulus be ing referred to hereinafter as Ty.

carbonates (e.g. lbers, conveyor belts, shoe soles, etc.).

Other uses are impact modifiers, tackifiers, plasticizers, ad-

hesives and binders.

The novel copolycarbonates of this invention may be prepared by any of the know methods for producing block copolycarbonates such, for example, as the ester exchange method, the interfacial method or the solution method disclosed in the article Elastomeric Polycarbonate 'Block Copolymers-by Eugene P. Goldberg, Journal of Polymer Science, C4, 707 (1963).

The preferred method for the production of the block copolycarbonates of this invention is the known solution technique disclosed in the above referred to Goldberg article as well as US. Goldberg Pat. 3,161,615. In this method, the appropriate diol reactants are incorporated in a suitable organic base such as a tertiary amine (e.g. pyridine, substituted pyridines such, for example, as 3- methyl-pyridine, 4-methyl-pyridine, 3-chloro-pyridine and given off during the reaction. Although the phosgene reaction can be carried out over a wide range of temperatures, for example from below -10 C. to over 100 C., the reaction proceeds satisfactorily at to 50 C.

In employing the preferred solution technique, the block copolycarbonates of this invention may be prepared by a direct one step reaction of phosgene or any other dibasic acid halide with a dihydric phenol and an appropriate hydroxyl terminated polylactone (molecular weight 500- 3000) in an appropriate solvent (e.g. methylene chloride/ pyridine solvent) or by a two-step technique wherein a bischloroformate of a dihydric phenol is first formed and then reacted with more dihydric phenol and the hydroxyl terminated polylactone, or a two-step process wherein both the bischloroformate of the dihydric phenol and bischloroformate of the hydroxyl terminated polylactone are first formed and then reacted with more dihydric phenol.

In all of the above-mentioned processes, the total number of moles of acid halide end groups must be aproximately equal to the total number of hydroxy end groups. By employing the two-step techniques a block copolycarbonate of a more regular structure is formed.

In forming the block copolycarbonates of this invention, the carbonate precursor (e.g. phosgene) is used in an amount equal to at least the molar concentration of the dihydric phenol and hydroxyl terminated polylactone.

.In forming the block copolycarbonates of this invention, the dihydric phenols suitably employed include the entire class of such compounds heretofore utilized in the preparation of polycarbonate resins by prior known conventional methods. In general, such dihydric phenols are usually defined as being a mononuclear or polynuclear phenol in which the two hydroxyl groups are directly attached to different nuclear carbon atoms of the same or different aromatic nucleus. The class of suitable dihydric phenols is quite large and includes those compounds described in US. Pat. 2,950,266G0ldb1um, and US. Pat. 2,964,797Pielstocker et al. and my US. Pat. 3,223,677, which correspond to the general formula T JL .ML U.

wherein R is hydrogen or a monovalent hydrocarbon radical, for example, alkyl radical (e.g., methyl, ethyl, propyl, isopropyl, butyl, decyl, etc.), aryl radicals (e.g. phenyl, naphthyl, biphenyl, tolyl, Xylyl, etc.), aralkyl radicals (e.g. cyclopentyl, cyclo-hexyl, etc.) as well as monovalent hydrocarbon radicals containing inert substitutents therein, such as halogen (chlorine, bromine, fluorine, etc.). It will be understood that where more than one R is used, they may be the same or different. R is selected from the group consisting of an alkylene and alkylidene residue such as methylene, ethylene, propylene, propylidene, isopropylidene, butylene, butylidene, amylene, isoamylene, isoamylidene, cyclohexylidene, etc. R can also be a silane radical or can be a polyoxy such as polyethoxy, polypropoxy, polythioethoxy, polybutoxy, polyphenylethoxy or polyorganosiloxy, for example, polydimethyl ethoxy or polyorganosiloxy, polymethylphenyl siloxy, etc., or an ether, a sulfur-containing linkage such as sulfide, sulfoxide, sulfone, a carbonyl, a tertiary nitrogen or a silicon-containing linkage such as silane or siloxy. R can also consist of two or more alkylene or alkyidene groups, such as above, separated by the residue of an aromatic nucleus, a tertiary amino radical, an ether radical or by a carbonyl radical, a silane or siloxy radical or by a sulfur-containing radical such as sulfide, sulfoxide, sulfone, etc. Other groupings which can be represented by R will occur to those skilled in the art. Ar is the residue of an aromatic nucleus, Y is a substituent selected from the group consisting of (a) inorganic atoms, (b) inorganic radicals, and (c) organic radicals, (a), (b) and (c) being inert to and unaffected by the reactants and by the reaction conditions, In is a Whole number including zero to a maximum equivalent to the number of replaceable nuclear hydrogens substituted .4 on the aromatic hydrocarbon residue, 2 is a whole number including zero to a maximum determined by the number of replaceable hydrogens on R s ranges from zero to 1, t and u are whole numbers, preferably 1. When s is zero, however, either t or u may be zero and not both.

In the dihydric phenol compound, the substituent Y may be the same or different, as may be the R. Among the substituents represented by Y are halogen (e.g. chlorine, bromine, fluorine, etc.) or oxy radicals of the formula OZ, where Z is a monovalent hydrocarbon radical similar to R, or monovalent hydrocarbon radicals of the type represented by R. Other inert substituents such as a nitro group can be represented by Y. Where s is zero in Formula I, the aromatic nuclei are directly joined with no intervening alkylene or alkylidene or other bridge. The positions of the hydroxyl groups and Y on the aromatic nuclear residues Ar can be varied in the ortho, meta, or para positions and the groupings can be in a vicinal, asymmetrical or symmetrical relationship, where two or more of the nuclearly bonded hydrogens of the aromatic hydrocarbon residue are substituted with y and the hydroxyl group. Examples of dihydric phenol compounds that may be employed in this invention include 2,2-bis (4-hydroxyphenyl -propane Bisphenol-A) 2,2-bis 3,5 -dichloro-4-h ydroxyphenyl) propane;

2,4'-dihydroxydiphenyl-methane;

bis- 2-hydroxyphenyl -methane;

bis- 4-hydroxyphenyl) -methane;

bis- 4-hydroxy-5 -nitrophenyl -methane;

bis- 4-hydroxy-2,6-dimethyl-3-methoxyphenyl methane;

1, 1 -bis- (4-hydroxyphenyl -ethane;

1,2-bis- 4-hydroxyphenyl -ethane;

1,l-bis-(4-hydroxy-2-chlorophenyl)-ethane;

1, l-bis- 2,5 -dimethyl-4-hydroxyphenyl) -ethane;

1,3-bis- 3-methyl-4-hydroxyphenyl) -prop ane;

2,2-bis- 3-phenyl-4-hydroxyphenyl -propane;

2,2-bis- 3-isopropyl-4-hydroxyphenyl -propane;

2,2-bis- 4-hydroxynaphthyl -propane;

2,2-bis- 4-hydroxyphenyl) -pentane;

3,3-bis- 4-hydroxyphenyl) -pentane;

2,2-bis- 4-hydroxyphenyl) -heptane;

bis- 4-hydroxyphenyl) -phenyl methane;

bis- 4-hydroxyphenyl) -cyclohexyl methane;

1,2-bis- 4-hydroxyphenyl) l ,2-bis- (phenyl) ethane;

2,2-bis-(4-hydroxyphenyl)-1,3-bis-(phenyl) -pr0pane;

2,2-bis-(4-hydroxyphenyl) -1-phenyl propane;

and the like. Also included are dihydroxybenzenes typified by hydroquinone and resorcinol, dihydroxydiphenyls such as 4,4-dihydroxydiphenyl; 2,2-dihydroxydiphenyl; 2,4'-dihydroxydiphenyl; dihydroxynaphthalenes such as 2,6-dihydroxynaphthalene, etc. Dihydroxy aryl sulfones such as bis-(p-hydroxyphenyl)-sulfone; 2,4'-dihydroxydiphenyl sulfone; 5-chloro-2,4-dihydroxydiphenyl sulfone; 5'-chloro-Z,4-dihydroxydiphenyl sulfone; 5'-chloro-2',4- dihydroxydiphenyl sulfone; 3' chloro-4,4-dihydroxydiphenyl sulfone, bis(4-hydroxy phenyl)biphenyl disulfone, etc. The preparation of these and other useful sulfones is described in Pat. 2,288,2 82Huissman. Polysulfones as well as substituted sulfones using halogen, nitrogen, alkyl radicals, etc. are also useful. Dihydroxy aromatic others such as p,p'-dihydroxydiphenyl ether; the 4,3'- 4,2- 3,3'- 2,2'- 2,3- etc. dihydroxydiphenyl ethers; 4,4-dihydroxy-2,6-dimethyldiphenyl ether; 4,4'-dihydroxy-2,S-dimethyldiphenyl ether; 4,4'-dihydroxy-3,3'-di-isobutyldiphenyl ether; 4,4-dihydroxy-3,3-diisopropyldiphenyl ether; 4,4'-dihydroxy-3,2-dinitrodiphenyl ether; 4,4'-dihydroxy-3,3-difluorodiphenyl ether; 4,4-dihydroxy-2,3'-dibromodiphenyl ether; 4,4'-dihydroxydinaphthyl ether; 4,4-dihydroxy-3,3'-dichlorodinaphthyl ether;

2,4-dihydroxytetraphenyl ether; 4,4'-dihydroxypentaphenyl ether; 4,4'-dihydroxy-2,6-dimethoxydiphenyl ether; 4,4'-dihydroxy-2,S-diethoxydiphenyl ether, etc.

Mixtures of the dihydric phenols can also be employed and where dihydric phenol is mentioned herein, mixtures of such materials are considered to be included. Preferably the dihydric phenol is a gem-bis-(hydroxyphenyl) alkane in which the central alkylidene radical contains from 1 to 6 carbon atoms.

As indicated hereinbefore, the lactone units in the polylactone blocks of the block copolymers of this invention have the following structure:

wherein R is hydrogen or monovalent hydrocarbon as defined above and g is an integer of 5 to 6. Illustrative of such lactone units are epsilon-caprolactone units, e.g., -[CH COO, monoalkyl epsilon-caprolactone units, e.g., --C(CH )H(CH. CO,

and the like, dialkyl epsilon-caprolactones, e.g.,

C(C H )HC(C H )H(OH COO '-CH2C(C3H7)HCH3C(CH3)HCH2COO, and the like, cycloalkyl, aryl alkaryl and aralkyl epsilon-caprolactones, -e. z)z s 11) z)z C(CH C H )H(CH COO-, and the like wherein C H is cyclohexyl, C H is phenyl and CH C H is benzyl.

The polylactone segments are provided, for example, by using as a reactant a polylactone diol represented by the formula:

wherein R R g and n are the same as in Formula II.

The following examples illustrate the preparation of block-copolycarbonates of this invention by direct phosgenation of a mixture of the dihydric phenol and the polylactone diol in methylene chloride/pyridine solvent (60/40 wt. ratio). The same general procedure described with respect to Example 1 was used in Examples 2 to 5.

In the tables which appear hereinafter a number of abbreviations are used. The abbreviations are now given followed by the full names.

Coag. polym.Coagulated polymer RV-Reduced viscosity React. mixt.-Reaction mixture Mod.-Modulus Str.-Strength Elong. Elongation P. imp.Pendulum impact --about m. Mole-millimole Amt.Amount M01. wt.Molecular weight Cryst.--Crystallization T.M.Tensile modulus 100% M-100l% modulus 300% M300% modulus T.S.-Tensile strength E.Elongation Examples 1 thru 5 which follow illustrate the preparation of block copolymers from a mixture of a polycaprolactone diol of a molecular weight of 840 (Poly- 6 lactone I) and bisphenol A via the direct phosgenation method.

Reduced viscosity (RV) is determined by dissolving a 0.2 gram sample of polymer in chloroform in a ml. volumetric flask so that the resultant solution measures exactly 100 ml. at 25 C. in a constant temperature bath. The viscosity of 3 ml. of the solution which has been filtered through a sintered glass funnel is determined by a viscometer at 25 C. Reduced viscosity values are obtained from the equation:

Reduced viscosity= clt wherein:

1' is the efliux time of the pure solvent z is the efilux time of the polymer solution c is the concentration of the polymer solution expressed in terms of grams of polymer per 100 ml. of solution Glass transition temperature (Tg), commonly referred to as the second order phase transition temperature, refers to the inflection temperatures found by plotting the resilience (recovery from one percent elongation) of a film ranging in thickness from 3 to 15 mils against the temperature. See Brown, Textile Research Journal, 25, 891 (1955).

EXAMPLE 1 Preparation of a block-copolycarbonate from Polylactone I and bisphenol-A Reagents:

Polylactone I (see Table I) Bisphenol-A-high purity, M.P. 155-156 C.

Methylene chloride and pyridine, dried over 4A molecular sieves. Phosgene-Matheson99 purity Apparatus.A three-neck 500 ml. flask equipped with mechanical stirrer, reflux condenser, thermometer, and dry-argon and phosgene inlet-tubes. The argon is circulated over the reaction mixture; phosgene is bubbled into the mixture. The addition of phosgene was made from a tank placed on a solution balance.

lExperiment.Polylactone I, 12.83 gins. (0.01527 mole;

45 wt. percent, 18.2% m. based on the total diol charge), bisphenol-A, 15.67 grns. (0.06864 m.; 55 Wt. percent, 81.8 mole percent based on the total diol charge), pyridine, 100 ml., and methylene chloride, ml., were charged into the flask. Stirring and circulation of dry argon were started. The contents in the flask were cooled to -20 C. Addition of phosgene was started. Approximately 8 grns. (96% of the required amount) of phosgene were added to the mixture within 11 minutes. A cooling ice-water bath was maintained around the flask during that period of time. The temperature of the mixture rose to 30 C. A white precipitate of pyridine hydrochloride formed. The cooling bath was removed and the rate of the addition of phosgene substantially decreased. After 14 additional minutes, the reaction mixture was very viscous and practically colorless. Its temperature was 30 C. The phosgenation was stopped. Reaction cycle: 25 minutes. The polymer solution was coagulated in 2 liters of methanol. The white fluff was washed twice with methanol and twice with distilled water. Each wash: 2 liters of solvent; 5 minutes of vigorous stirring in the Waring Blendor. It was then dried at about 60 C. (under vacuum) till constant weight. Yield: 93.6% RV (CHCI 25 C.; 0.2 g./10O ml.)=1.35.

EXAMPLES 2-5 Following the same general procedure as used in Example 1, four other block copolycarbonates (Examples 2-5) were prepared varying the amounts of reactants. Examples 15 are summarized in Table I.

7 Examples 6 thru 9 (Table II) relate to block-copolyture of various polycaprolactone diols and dihydric phecarbonates prepared by direct phosgenation of a mixture nols other than bisphenol A. of polycaprolactone diol of a molecular Weight of 1993 Tables A and B summarize various physical proper- (Polylactone H) and bisphenol A. ties of a number of the block copolycarbonates of this Examples 10 thru 14 (Table III) illustrate block invention. polycarbonates prepared by direct phosgenation of a mix- TABLE I Block-Copolycarbonates from Bisphenol A and Polylactone I l Polylactone I Bisphenol A Polymerization Color Polymer Percent Percent Percent Percent Time Yield Example No. wt. mole 2 wt. mole 2 (hr.) Temp. 0.) Reaction mixture Coag. polym. RV 3 (percent) 2 65 33. 51 35 66. 49 1. 08 -31 Pract. colorless White 1. 90.7 3 60 28. 93 70. 07 0. 5 1. 94 93. 3 4 55 24. 92 75. 08 0. 7 2. 72 91. 3 5 21. 37 50 78. 63 0. 48 1. 49 93. 9 1 45 18. 2 81. 8 0. 42 1. 35 93. 6

l 1 iiglyilatctoue I is a polycaprolactone of mol. wt. 840. It is obtained by the base-catalyzed polymerization of e-caprolactone with diethylene glyco as a or.

2 The percentages are based upon the total diol charged only.

3 All RVs in CHCI; at 25 C. (0.2 g./100 ml.).

TABLE II Block-copolycarbonates from Bisphenol-A and Polylactone II 1 Polylactone II BisphenoI-A Color Polymer Percent Percent Percent Percent Reaction Yield Example No. wt. mole wt. mole 2 time (hr) 5 Reaction mixture Coagulated polym. RV 4 (percent) 14.66 10 85. 34 2 Pract. colorless White 2 18 94. 8

55 12. 26 45 87. 74 0 75 Ligh -yellow 1. 85 91. 7

50 10. 26 50 89. 74 0. 33 Colorless 1. 86 94 45 8.56 55 91. 44 0. 58 Pract. colorless 1. 60 93. 6

Pplylactonel is a polycaprolactone, molecular weight 1,993, obtained by the base-catalyzed polymerization of e-caprolactone with diethylene g you as 1m 1a or.

7 The percentages are based on the total diol charge only.

3 The temperature in all runs was kept within 1833 C.

4 All RVs in 011013, at 25 C. (0.2 g./100 ml.).

TABLE III Block-copolycarbonates from dihydrio phenols other than Bisphenol-A Amorphous block Bisphenol Color Polymer Percent Percent Percent Percent Reaction Yield Example No. wt. mole wt. mole 1 time (hr.) 2 React. mixt. Coag. polym. RV 8 (percent) Remarks 10 Polylactoue I Hydroquinone 19. 57 35 80.43 0. se Yellow Light yellow. 0.20 91. 2 Polymers crystallized from radiation.

11 Polylactone I Hydroquinone 23.4.2 30 76.58 0.84 .do -.do 0.46 92.9 Do. 12 Polylactone I Hydroqnlnone 28. 21 25 71. 0.5 Light brown. ..d0 0. 49 85.9 Do. 13 Polylactone II 4,4 -dihydroxybenzophenone 60 13. 88 40 86.1 0. 53 Brown Brown 0. 33 63.7 Do.

14..-.- Polylactone II Dihydroxybenzophenone 60 13. 88 40 86. 12 0. 84 Dark yellow Tan 6 0.80 94. 7 Color is probably due 0 impurities in starting diphenol.

1 The percentages are based on the total diol charge only.

2 The temperature of the reactions was kept within the interval of -1035 C. 3 All RVs in m-cresol, at 25 C. (0.2 g./ ml.).

4 Mixture of isomers.

6 This RV was run in CHCIz, at 25 C. (0.2 g./100 ml.).

6 Initial solution of reactants was also dark yellow.

moieties, aliphatic diol moieties, the aforementioned moieties being divalent radicals obtained by removal of hydroxyl groups from the extending agent. The link between the divalent radical extender and the divalent polylactone residue is either a carbonate group or an ester group.

The extending agents may be saturated aliphatic, saturated cycloaliphatic or aromatic. The aliphatic and cycloaliphatic extenders may also contain olefinic unsaturation. Such unsaturation is for the following reasons:

(1) The extended diols can be vulcanized with sulfur to give cross-linked elastomers; and

(.2) The extended diols can be used as base resin in millable gum compositions; and,

(3) The block copolycarbonates based on these extended diols can be cross-linked to give products having desirable solvent resistance.

Generally, the extending agent has a molecular weight in the range of 60 to 2,000.

The dihydric phenol suitably employed as an extender includes any of the diphenol heretofore mentioned as reactants in the production of block copolycarbonates of this invention.

The aliphatic diols that may be used as extenders include cycloaliphatic, straight and branched chain diols free of substituent groups reactive toward the other reactants of the reaction system. In general, these diols conform to the formula (V) HO-Y-OH in which Y can be an alkylene group such as ethylene, propylene, butylene, amylene, isoamylene, neopentylene and the like; an alkenylene group or two or more alkylene or alkylidene groups connected by a nonalkylene or nonalkylidene group such as an ether linkage, alkylene groups having pendant double bonds such as monoallyl ether of trimethyol propane:

alkylene groups containing aromatic residues, a carbonyl linkage, a sulfur containing linkage such as sulfide, sulfoxide or sulfone, cycloaliphatic residue such as cyclopentyl, cyclohexyl, or a silicon-containing linkage such as silane or siloxy; and a cycloaliphatic group such as cyclopentylene and cyclohexylene. Substitutent groups on the Y group can be halogen, nitro, cyano or aryl, but reactive groups such as hydroxyl (other than the two such groups necessarily present) amine, and carboxyl are to be avoided if cross-linking of the polymer is to be avoided.

The dibasic organic acids that may be used as extenders conform to the general formula:

is employed as an additional reactant. In Formula VI, D represents either a hydroxyl or carboxyl group, and G is an alkylene or alkylidene or group such as ethylene, propylene, propylidene, isopropylidene, butylidene, butylene, isobutylidene, amylene, isoamylene, amylidene, isoamylidene, neopentylene; a cycloaliphatic group such as cyclopentylene, or cyclohexylene; divalent hydrocarbon groups free of acetylenic unsaturation, an aromatic radical such as phenylene, naphthylene, biphenylene, substituted phenylene, etc.; two or more aromatic groups connected through nonaromatic linkages such as those defined by R in Formula III; an aralkyl radical such as tolylene, xylylene, etc. G should be free of amine, hydroxyl and carboxyl groups, i.e., the acid of Formula VI should be a 12' difunctional compound in the present reaction system. As used hereinafter the structure is termed the residue of a dicarboxylic acid, and the structure o ltaol L .l

is termed the residue of a monohydroxymonocarboxylic acid.

Included within the scope of this invention are the saturated, aliphatic dibasic acid extenders derived from straight chain paraffin hydrocarbons, such as malonic, dimethyl malonic, succinic, glutaric, adipic, pimelic, suberic, azelaic and sebacic acid. Also includede are the halogen-substituted aliphatic dibasic acids. Aliphatic carboxylic acids containing hetero atoms in their aliphatic chain, such as thio-diglycollic or diglycollic acid can also be used. Also useful are oletinically unsaturated acids as, for example, maleic or fumaric.

Example of suitable aromatic and aliphatic-aromatic dicarboxylic acids which may be used as extenders are phthalic, isophthalic, terephathalic, homophthalic, 0-, m-, and p-phenylenediacetic acid; the polynuclear aromatic acids such as diphenic acid, and 1,4 napthalic acid, isopropylidene bisphenoxyacetic acid.

Examples of hydroxy acid extenders are the aliphatic hydroxy acids such as hydroxybutyric acid, glycollic acid and lactic acid. Examples of aromatic and aliphaticaromatic hydroxy acids are mandelic acid, p-, mand 0- hydroxy benzoic acid. The hydroxy-substituted long-chain fatty acids, such as 12-hydroxystearic acid may also be used. cycloaliphatic acids including tetrahydrophthalic, tetrahydroterephthalic, tetrahydroisophthalic, 3,6 endomethylenetetrahydrophthalic acid, hexachloro-3,6-endomethylenetetrahydrophthalic acid or camphoric acid may also be used.

The extended polylactone diols produced in accordance with this invention are difunctional hydroxy terminated stable materials. While these low melting or liquid polymers are particularly useful in forming novel block copolycarbonates, they are useful in several other areas including as the polyol reactant used in producing polyurethane elastomers, spandex fibers, polyurethane sealants and flexible polyurethane foams as well as placticizers and tackifiers for various resins (e.g. polyvinyl chloride and its copolymers).

In producing the extended polylactone diols of the present invention the same solution technique using direct phosgenation for producing the block copolycarbonates of this invention may be employed.

The reaction is generally carried out at a temperature in the range of O30 C. Higher temperatures are preferably avoided because of undesirable secondary reactions that may occur at temperatures above 30 C.

In order to achieve the production of high molecular weight extended diols, it is necessary for the number of acid halide groups to be approximately equal to the number of hydroxyl groups. Accordingly, with gaseous reactants such as phosgene which are difiicult to control, in order to avoid an excess amount in the reaction, most of the gaseous reactant (but less than the stoichometric amount) is passed rapidly in the reaction mixture with the remaining amount introduced slowly to bring the total amount in the reaction mixture to stoichometric proportions.

By the above precautionary steps in introducing phosgene, an undesirable excess of phosgene is avoided. As indicated earlier, generally an excess of any of the reactants reduces the molecular weight of the resulting product.

It has been found that in the production of extended diols by the solution technique using a tertiary base, the higher the amount of tertiary base, the more efiicient is the phosgene utilization.

The ratio of polyactone diol to extender may vary. When the extending agent is an aliphatic or cycloaliphatic compound the polylactone diol is in an amount from 0.1 to moles per mole of extender. When the extender is an aromatic compound, the polylactone diol is in an amount from 1 to 10 moles per mole of extender.

Examples -28 which follow relate to the preparation of extended polylactone diols in accordance with the present invention. A typical procedure for producing an extended polylactone diol is shown in detail in Example 15 and a preparation of a series of Polylactone III/Polyether I derived extended diols (Examples 1622) is summarized in Table IV.

Examples 23-25 using neopentyl glycol and bisphenol A as extenders are summarized in Table V.

In Table VI is shown the percent hydroxyl and molecular weights of many of the extended diols summarized in Table IV and V. In Table VII, there is summarized additional examples of extended diols of this invention. Table VIII discloses melting point and glass transition data for three extended diols of the invention.

EXAMPLE 15 Preparation of the extended diol from Polylactone III and Polyether I (1:1 molar ratio) Apparatus.A 12-liter, round-bottomed flask equipped with a mechanical stirrer, reflux condenser, thermometer, and dry-argon and phosgene inlet-tubes. The argon is circulated over the reaction mixture; phosgene is bubbled into the mixture. The addition of phosgene was made from a tank placed on a solution balance.

Reagents:

Polylactone III and Poleyether I. Methylene chloride and pyridine dried over 4A molecular sieves. Phosgene about 99% purity.

Experiment.Into the flask were charged: 330 gms. (0.6226 mole) of the Polylactone III, 124.52 gms.

(0.6226 mole) of Polyether I, 5.6 1. CH CI and 625.4 ml. (7.7735 moles; 212.13 mole percent excess over the amount stoichiometrically required) of pyridine. The clear, practically colorless solution was cooled to about 4 C. Addition of phosgene at a rate of about 3 gms. COCl 2 minutes (121 mmole percent/min.) was started. Approximately 101 gms. of phosgene (about 82% mole) were added at this rate (addition time: 72 minutes). During this period of time the temperature rose to 30 C.; the mixture was cooled to 11 C., and the slow addition of phosgene (rate: 4 g. per 10 min. or 3.2 mmole percent/ min.) started. It was continued until a total of 139 gms. (12.5 mole percent excess over the amount required) of phosgene was added. A White precipitate of pyridine hydrochloride formed; the temperature of the reaction rose to 265 C. at the end of the phosgenation. The reaction solution was very light-pink.

The excess of pyridine was neutralized with a solution of 438 ml. conc. hydrochloric acid in 2 liters of distilled water. The pink color disappeared on neutralization and a very light yellow organic layer was obtained. The twophase, aqueous acid/methylene chloride solution, system was stirred for 1 hr. and then decanted. The organic layer was given a series of water-washes until the aqueous layer was neutral at the end of the Wash. Total number of washes required: 4; each wash: 2 liters of distilled water; stirring times were 0.5 hr. for the first three, and 1 hr. for the last wash. Emulsions formed on washings and were broken by the addition of variable amounts of methanol.

The organic layer was dried over magnesium sulfate, filtered and evaporated. The yellow, clear, viscous residue was then dried til constant weight at about C. under house vacuum. It was considered as being at constant weight when its weight loss over 24 hrs. under the drying conditions mentioned above was lower than 0.50%.

The yield of residue was 96.1%; RV (CHCl 25 C.; 0.2 g./100 ml.)0.49.

All of the other extended diols of Examples 1=622 (Table IV) were prepared using similar techniques. Molecular weights of the products were determined by vapor phase osmometry and by acetylation of the hydroxyl end-groups.

TABLE IV Extended diols based on Polylactone III B and Polyether I b a Pyridine C0011 Slow Extended diol (mMolo Amount Excess percent/ Yleld Example No. ms.) (percent) mm.) (percent) RV d Color/appearance a 758. 53 285. 5 1. 92. 6 0. 44 Golden-yellow, viscous clear liquid. 758. 53 285.5 1. 6 95. 7 0. 44 Same as 1. 758. 53 285. 5 1. 6 93. 9 0. 44 Do. 758. 53 285. 5 3. 2 91. 9 0. 82 Do. 758. 53 285 5 3. 2 91. 04 0. 85 Light-brown, viscous, clear liquid. 614.11 212. 13 3. 2 91. 3 0.67 Same as 5. 614. 11 212. 13 3. 2 87.3 0.63 Do.

* 'Polylacetone III is a poly (e-caprolacetone) of mol wt. about 530 produced using diethylene glycol as an initiator.

' Polyether I is a polyethylene glycol of mol. wt about 200.

0 The charge in all of the experiments was: 330 gms. (0.6226 mole) of Polylactone III, 124.52 gms. (0.6226 mole) of Polyether I and 5.6 llters of methylene chloride. The fast addition of phosgene was performed at the rate of 12.1 mmole percent/min. and continued until 82% of it were added.

'All RVs in CHCls, at 26 0. (0.2 g./ ml.).

9 All extended diols displayed a typical ester odor.

TABLE V.-ADDITIONAL EXTENDED DIOLS (mmole per- I Pyridine cent/min.) Extended diol Example Solvent Amount Excess Fast Slow Yield No. Reagents and amounts amount (gms.) percent rate rate percent RV Color/apparatus 23- Polylactone III Neopentyl glycol CHzClg, 5.6 l. 1, 024. 04 420. 5 u 12. 1 3. 2 93. 2 0. 48 Golden-yellow, 330 gms; 0.6226 m. 68.84 gms; 0.6226 111. yilscugs, clear qul 24 do Neopentyl glycol CHzClz, 5.6 l. 682 420 d 12. 1 3. 2 95. 6 Do.

21.61 grns; 0.2075 in. 25 do Bisphenol-A 15.77 CH2C12, 5.6 l. 327. 9 200 d 12. 1 3. 2 97.4 0.29 Yellow, clear liquid,

gms; 0.0691 In. quite viscous.

a All RVs in CHClg, at 25 C. (0.2 g./100 1111.). b Po1y(e-caprolactone) of mol wt. about 530.

a Maintained until 82% of phosgene were added. d Maintained until 85% ot' phosgeue were added.

TABLE VI Percent hydroxyl and molecular weights of the extended diols Example N 0. Composition B RV b Percent HO M01 wt 26 Polylactone III plus Polyether I (1:1 molar ratio) 0.85 0. 594 5, 700 do 0. 30 0. 52 6, 500

* Polylactone III and Polylaetone II are poly (e-caprolactones) of molecular weights -530 and 2,000 respectively. Polyether I is glycol of average molecular weight about 200.

b All RVs in CHC1 at 25 C. (0.2 g./100 ml.). Calculated by assuming the presence of hydroxyl endgroups only.

a polyethylene TABLE VII Preparation of extended diols Final rate of phosgene addition (rnMoIe per- Yield Pyridine Example No. Component A Component B cent/min.) d (percent) RV b excess 2. 1 6O 0. 52 400 5. 52 0. 61 200 undo. 3. 9 77 0. 45 250 Hexanediol-LG 3.1 93 0.72 400 2,2-diethylpropanediol-I.3 2.3 90 0.47 160 2-ethylhexanediol-l .3 f 3. 3 94 0. 23 400 2. 1 77 l. 07 400 3. 7 90 0.78 400 0. 7 60 0. 36 500 0. 6 85 I. 03 500 1. 8 63 0. 70 500 2. 5 64 0.51 500 5. 3 87 0. 97 400 8 Prepared by method of Example at reaction temperature of C. b All RVs in CHCla, C. (0.2 grns./l00 m1.). e Polylaetone III is hydroxyl terminated poly (e-eaprolactone) mol wt. about 530. d Deserlbes the rate of additlon oi the last of phosgene. e A/B=l:1 (molar). f AlB=1z3 (molar). K AIB=211 (molar). Polyether I is a poly(ethylene glycol) oi mol wt. about 210.

TABLE VIII Melting points and glass transition temperatures of the extended diols Extended diol Example No. Composition Appearance RV Mol wt. Ig( C.)* Tz( 0.)

43 olylactone III plus Polyether I (1:1 molar ratio) Liquid 0. 28 **6, 100 45 20 44 1 0 do. 0. 51 17,300 19 do .-do 0.86 50,000 47. 5

=- All RV's in 011013, at 25 C (0.2/g./100 ml.). b Molecular weights by hydroxyl titration. See Table A.

Approximately.

50 aration of the block copolycarbonate elastomer is a twostep, one or two pot operation as shown:

PolylactonejDiol Extender Examples illustrating the preparation and properties of block copolycarbonates based on the extended diols are 55 tabulated hereinafter in Tables IX thru XIV. The prep- Solvent/pyridine C 0 C12 Extended Diol (Can be isolated or reacted in situ) Carbonate elastomers l based on preformed extended diols Z Polymer 4 Extended diol Polymerization Color Y 1d 10 Example N0. RV 3 Percent 110 M01 wt. Time (hr.) Temp. C.) React. mix. Cow. polym. RV 3 (percent) 0. 25 0. 59 5, 700 0.3 5. 20 Light yellow 1. 22 86. 4 0.30 0. 52 6, 500 0.5 16. ....d0 1.45 88 0.44 0.24 14, 000 0. 85 14-26 Praet. colorless. 1. 17 87. 7 0. 44 0. 24 I4, 000 1 0-23 Light-yellow. 1. 37 87. 5

1 All compositions were 6/4, extended diol/Bisphenol-A (based on total diol charge only) (6/4 is weight ratio). I All experiments were performed on 60 gms. of the extended diol and 40 gms. of Bisphenol-A. Methylene chloride (1 liter) was the solvent. Pyridine mole percent excess over the amount stoichiometrically required) was the catalyst and acid acceptor. The extended diols were prepared by phosgenation oi equimoler amounts of Polylactone III and Polyether I.

3 All RVs in CHCIQ at 25 C. (0.2 g./ m1.).

4 The reaction mixtures were treated with aqueous hydrochloric acid and then washed with distilled water till neutrality. Polymers were isolated via coagulation in excess methanol.

TABLE X Primary crystallinity in carbonate elastomers based on preformed extended diols 1 T2 C.) after exposure at 100 C. for- Cryst. time Extended d1ol, RV 2 oi 0.25 0.5 1 3 5 8 13 16 24 at 100 C 5 Example No. mol wt. elastomer hr. hr. hr. hr. hrs. hrs. hrs. hrs. hrs. hrs. (hr.)

1 All compositions were 6/4 (by wt.), soft block/hard block, based on total diol charge only. Compression-molding temperature was 200 C.

2 RVs on flufi, prior to polymer molding (CI-I01 25 (3., 0.2 g./l00 ml.).

3 Temperature at which the tensile modulus of the elastomer is 100 psi. This is referred to as the T of the product.

The extended diols were prepared by phosgenation of equimolar amounts of Polylactone III and Polyether I.

Polylactone II (poly(e-caprolactone) mol Wt. 2,000)Polyether I.

TABLE XI Properties of the carbonate elastomers based on the preformed extended diols 1 2 Tensile Moi. wt. of Mold Degrees 0.

extended temp. RV of Annealed 4 Mod. Strength Elong. P. imp. (ft.

Example No. d1 1 C.) elastomer 3 (l) (p.s.i.) (p.s.i.) (percent) lbs/in. Tg T4 5 Ta 6 T2 5 1 All extended diols were prepared by phosgenation of equimolar amounts of Polylactone III and Polyether I.

Z All compositions were 6/4, extended diollblsphenol-Amased on total diol charge only) (6/4 is weight ratio).

3 RVs on starting fluff, prior to molding. All RVs 1n CHCIQ, 25 C.

4 At 100 0. times of annealing were: Example 455 hours, Example 468 hours; Example 468 hours; Example 47-15 minutes; Example 483 hours.

6 Temperature at which tensile modulus in 100 p.s.i., referred to often as polymer melting points. See Table A.

(0.2 g./100 ml.). 8% Table A.

TABLE XII Carbonate elastomers based on extended diols l Elastomer Example No. Extended diols from 2 RV 8 Yield (percent) Polylactone II plus Bisphenol-A 1, 00-2. 95+ 49.- Polylactone II plus neopentyl glycol- 1. 89 50 Polylactone II plus 1,2 propylene glycol. 1. 40 90. 7 51 Polylactono II plus tetraethylene glycol 2.06 89. 2 52 Poiylactone II plus Ester-Diol I 1. 72 86.1 53 Polylactone I plus neopentyl glycol 1 85 (0. 87, 1 72) 87. 1 (88. 8, 82.7) 54. Niax Polyol D-520 plus 1.2-propylene gylcol. 1. 35 87.0 55 Niax Polyol D-520 plus tetraethylene glycol 2.06 81. 8 56 Polylactone III plus tetraethylene glycol 0.96 6. 7

TABLE XIII Preparations of carbonate elastomers 2 3 Extended Diol Elastomer Example No. RV 5 -Mol. wt. RV Yield percent 1 Prepared by the 2-stcp one pot operation.

2 Preparations were carried out in CH Cl /pyridinge. Weight ratio extended diol/Bisphenol-A was 7/3.

3 All reaction mixtures were acid and water washed till neutrality prior to polymer isolation via coagulation in excess CH OH.

4 The extended diols were prepared by phosgenation of equlmolar amounts of Polylactone III and Polyether I.

5 All RVs in CHCIe at 25 C. (0.2 g./100 ml.).

As shown from the results reported in Tables XI-XIV, as the amount by weight of the hard block is increased,

3 All RVs in CHO13, at 25 C. (0.2 g./l00 1111.).

4 Several runs were performed. In some the reaction Bisphenol-A dichloroformate and Polylactone II (OH Cl pyridine) was used to prepare the extended diols. Mole ratios dichloroformate/Polylactone II were 3/4 and 7/8 in these two runs. 7

5 The formula of Ester-Diol I is:

the tensile modulus of the block copolymers is increased also.

As indicated earlier, and shown by the data of Tables X and XIV, the use of extended diols in the preparation of block copolymers of this invention permits a reduction in the annealing period. It has been found that alternative procedures may be used for reducing the annealing time.

One of such procedures involves the use of nucleating agents to increase the rate of primary crystallization. For example, crystallization rates of 15-30 minutes (at C.) have been obtained compared to the large number of hours (e.g. 6-24 hours) required for annealing in the absence of nucleating agents. Examples of materials that may be used as nucleating agents are high density polyethylene, polypropylene, Lexan, nylon, poly(ethylene terephthalate) microcrystalline cellulose, Cab-O-Sil, Marlex 50 polyethylene, carbon black, fullers earth, calcium carbonate, glycerine, and butyl benzyl phthalate.

As indicated earlier, the extent of annealing required for imparting the desired high temperature properties of block copolycarbonates having a. hard bisphenol A-polycarbonate may be reduced by the use of an extended polylactone diol or by the use of a nucleating agent. Another way of reducing the extent of annealing is to substitute, in part or in full, a dihydric phenol that yields a more readily crystallizable polycarbonate for the bisphenol A TABLE XIV Properties of Carbonate Elastomers 1 Crystaili- Mechanical properties after 16 hrs. at 100 0. RV 1 of cation 8 extended Elastomer at 100 C. T.M. 100% M 300% M T.S. E, T; Example No. dio RV 4 (hrs.) (p.s.i.) (p.s.i.) (p.s.i.) (p.s.i.) percent 0.) Remarks 0. 49 1. 35 1 2, 000 620 700 3,200 915 Fast crystallizer. Good tensile. 0. 49 1. 45 1 2, 000 600 800 3, 300 1, 000 Do.

1 All elastomers were prepared from the extended diol made by phosgenation oi equimolar amounts of Polylactone III and Polyether 1 weight ratio extended diol/Bisphenol-A was 7/3.

2 All RVs in 01101; at 25 0. (0.2 g./l 1111.). All RVs on fiufi, prior to molding. that yields a polycarbonate that crystallizes slowly. Examples of such typical dihydric phenols are hydroquinone, 4,4 biphenol, 4,4 dihydroxy diphenyl sulfone, 4,4 dihydroxy diphenyl sulfoxide and 4,4- diphenyl sulfide.

In Tables XV-XIX which follow, there are summarized the preparation and characterization of several hydroquinone and 4,4 biphenol based copolycarbonates. Such block-copolycarbonates were prepared by direct phosgenation of a mixture of hydroquinone or 4,4 biphenol (with or without bisphenol A) and the soft polylactone block. The process was essentially the same general method described hereinbefore with respect to the bisphenol A- a The term crystallization" etc. refers to primary crystallization throughout this table. This column gives the exposure times at 100 C. that were required for the development of primary crystallimty in the e astomer.

TABLE XV Block Copolycarbouates lrom Bisphenol-A, Hydroquinone, and Poly(e'caprolactones) Percent wt.

Color Polymer H dro- Example N 0. Soft block I qui r rone 74 Polylactone I--- 75 do Polylactone II. do

Bis A l The percentages are based on the total diol charge only.

I Poly actone I is a. poly(e-caprolactone) of mol. wt. -850; Polylactone I is a poly(e-capro1actone) of mol. wt. -2,000.

8 The temperature of the reactions was kept within the interval of 0-40 0.; all polymerizations were run in CHZCh/pyridine in the presence of a lar e excess of base (charge; 100 gms. total diol in 1,000 m1., total solvent; 6 4 by vol. Cinch/pyridine).

Reaction mixture Light-pink 1. 1 do d .-do Light-brown do Brown Light- Yield Remarks *Bisphenol-A.

Coag. polym.

Practically white 0 Light-yellow- Light-pink...

ite... do--. brown Light-pink..-

o Light-yellow TABLE XVI Properties of the Block Copolycarbonates from Bisphenol-A, Hydroquinone, and PolyQ-eaprolactones) Percent composition (by wt.) 2

Mold 100% 300% Hydro temp. T. Mod Mod. T. E T2 T3 T4 T Ex. No. Polylactone 2 Nlax Bis A quinone RV 3 0.) (psi) (p.s.i.) (psi) (p.s.i.) percent 0.) C.) (0.) C.)

ikuulzfidfi 5 1.70 200 "6 6 "6 5 5 "6 s mo e 720 560 3,6 0 13 2 1 5 74 Annealed 16 hrs. at 100 0. 1,500 840 4,500 5,500 330 All aged days 1, 700 1,120 4,890 4, 800 300 ded 75 "{Aunealed 16 hrs. at 0 Air aged 70 days ll n S mo e 76 Polylactone II- Annealed 16 Air aged 70 days Air aged 70 days 60 35 5 1.39 81 "{As molded 1 Polylactone I is a poiy(e-caprolactone) of mol. wt. about 850; Polylactone IT is a poly(e -caprolactone) of mol. wt. about 2,000.

2 All percentages based on total diol charge only.

' RV'E on starti g polymer find, not on compression molded films that were used to obtain the properties.

RVs in m-cresol, at 25 C. (0.2 g./100 ml.). 6 RVs in CHCla at 26 C. (0.2 g./100 m1.).

TABLE XVII Block copolycarbonates from hydroquinone and various soft blocks Soit block Hydroquinone Color Polymer a Reaction Percent Percent Percent Percent time Yield Example No. wt. mole 1 wt. mole 1 (hrs.) 2 React. mixt. Coag. polymer RV 4 (percent) Remarks 82 Polylactone I 6 35 80. 43 0. 84 Yellow Light-yellow 0. 20 91. 2 crystallized from 65 19. 57 reaction solution. 83 Poly lgctonezg Z2 30 76. 58 0. 84 -...-d .'......do 0. 46 92. 9 Do. 84 Polyigctonezg 21 25 71. 79 0. Light-brown do 0. 49 85. 9 Do. 85 Polygctone37 20 65. 43 2. 33 .do White 0.90 89.6 Do. as Polygctonegzz 15 57.38 0. e Light-yellow do 1.15 88 Do. 87 Polylactone I 10 45. 69 0. 4 Light-brown..- Tan O. 77 85.1 Polymer was soluble in 90 54. 31 CHC13 and in the reaction solution. 88 Polylactone I 5 5 28. 49 0.83 Brown Light-pink 1. 22 87. 9 Sticky, rubbery 95 71. 51 polymer; soluble in 01101 and in reaction solution. 89 Polylactone I1 20 81. 58 0.75 Dark-pink do 0. 77 88. 4 crystallized from 80 18. 42 reaction solution.

1 The percentages are based on the total diol charge only.

1 The temperature of the reactions was kept within the interval of about 1035 C. All polymerizations were run in OHzClz/pyridine in the presence of a. large excess of base.

8 All polymers were isolated by coagulation of the reaction solution in excess methanol, followed by several methanol and distilled water washes of the solid polymer in the Waring Blendor.

I All RVs in m-eresol, at 25 C. (0.2 g./l00 ml.). Polylactone I is a poly(e-caprolactoue) of mol wt. about 850; Polylactone II is a poly(e-caprolactone) oi mol wt. about 2,000.

TABLE XVIII Additional hydroquinone-based carbonate elastomers H ydro- Color Polymer 3 qumone, Reaction Example percent time, React. Coag. Yield, number Soft block, percent wt. wt. hrs. mixt. polymer 2 RV 6 percent Remarks 90 Extended diol of Example 28, RV =0.50; 80%.-- 20 5 2.33 Light Tan 1. 21 81.9 Crystallize brown. from solution. 91 Extended diol 3 of Example 28, RV =0.50; 85%.... 6 1. 5 do do 1. 32 82.4 Do. 92. Extended diol 3 of Example 43, RV =0.28; 80%.-. 7 1. 4 Light tan. Light tan. 0. 96 93. 4 Do. 93. Extended diol 3 of Example 44 plus 20 of B1s- 20 a 1. 1 do White-.. 05 88. 9 Do.

phenolA, RV =0.51; 60%.

1 Percentages based on total diol charge only.

5 Reactions run in the temperature interval of -0-30 0.; polymers were isolated by coagulation of the reaction mixtures in excess methanol, followed by methanol and distilled water washes of the flufi in the Waring Blendor.

* Extended diols from Polylactone III (a poly-ecaprolactone of mol. weight -530) and Polyether I, at a 1:1 mole ratio.

4 RV's in CHCL; at 25 C. (0.2 g./l00 1111.). 5 RVs in m-cresol, at 25 C. (0.2 g./l00 ml Reactions run in CHzClz/pyridine with a260% mole excess pyridine.

1 Reactions run in s-TCE/pyridine with a 260% mole excess pyridine.

8 Reaction run in CH Olz/pyridine in the presence of a large excess of pyridine.

TABLE XIX Block copolycarbonates from Polylactone I and 4,4-bisphenol Polylac- 4,4'-bistone, perphenol, Yield, Example number cent wt. percent wt. percent RV 1 1 RVs in m-cresol, at 25 C. (0.2 g./l00 ml.). 2 Polylactone I is a poly-e-caprolactone of mol wt. 850.

What is claimed is: 1. A film forming block copolycarbonate consisting essentially of (l) carbonate groups by the formula 0 H -O O 0- (2) divalent polylactone moieties containing a plurality of lactone groups represented by the formula:

'ECREEECOO- wherein R is selected from the class consisting of hydrogen and monovalent hydrocarbon groups free of unsaturation and having 1 to 18 carbon and g is an integer of 5 or 6; and, (3) divalent aromatic carbocyclic residues derived from a dihydric phenol by removal of the hydroxyl groups, each of at least some of said carbonate groups being attached to two aromatic carbocyclic residues, and each of at least some of the carbonate groups linking one of said aromatic carbocyclic residues to one of said divalent polylactone moieties, the polylactone moieties being in an amount from about 50 to by weight of the total composition.

2 The block copolycarbonate according to claim 1 in which the aromatic carbocyclic groups are derived from a bis(4-hydroxyphenyl) alkane in which the central alkylidene or alkylene group contains from 1 to 8 carbon atoms.

3. The block copolycarbonate according to claim 1 in which the aromatic carbocyclic groups are drived from a gem-bis(4-hydroxyphenyl) alkane in which the central alkylidene group contains from 1 to 8 carbon atoms.

4. The block copolycarbonate according to claim 1 have the structure wherein the aromatic carbocyclic residue is a bisphenol A residue.

5. The block copolycarbonate according to claim 1 wherein the aromatic carbocyclic residue is a hydroquinone residue.

6. The block copolycarbonate according to claim 1 wherein the aromatic carbocyclic residues are a mixture of bisphenol A residues and hydroquinone residues.

7. The block copolycarbonate of claim 1 wherein the aromatic carbocyclic residue is a 4,4 biphenol residue.

8. The block copolycarbonate according to claim 1 in which g in the polylactone moiety is 5.

9. The block copolycarbonate according to claim 1 wherein the polylactone moiety contains one or more extender moieties selected from the group consisting of dihydric phenol moieties, dicarboxylic acid moieties or alkylene glycol moieties.

10. A film forming block copolycarbonate represented by the formula wherein R is a divalent organic radical; and,

wherein R is selected from the class consisting of hydrogen and monovalent hydrocarbon groups free of aliphatic unsaturation and having 1 to 18 carbon atoms and g in an integer of 5 or 6; and

wherein DH is a divalent aromatic carbocyclic group derived from a dihydric phenol by removal of the hydroxy groups; and,

wherein x and y have values so that the relative weight of the polylactone blocks are 50 to 80% by weight and the dihydric phenol polycarbonate blocks are 50 to 20% by weight of the total composition; and,

wherein n is in an integer so that the molecular weight of the polylactone segment is in the range of 500 to 3,000; and,

wherein m has a value so that the block copolymer has a reduced viscosity of at least 0.70 in chloroform 24 (0.2 gram block copolymer/ ml. solution at 25 C.; and, wherein the block copolycarbonate has a glass transition temperature below 0 C. and a tensile modulus of 100 psi. at a temperature of C. 11. A block copolycarbonate as claimed in claim 10 wherein R is a divalent hydrocarbon radical.

12. A block copolycarbonate as claimed in claim 10 wherein R is a divalent aliphatic radical.

13. A block copolycarbonate as claimed in claim 10 wherein R is two or more divalent hydrocarbon radicals joined by ether oxygen.

References Cited UNITED STATES PATENTS 3,312,753 4/1967 Bailey et a1. 260860 3,489,819 I/ 1970 Busler 260-823 3,502,623 3/ 1970 Hurworth et a1. 260860 WILLIAM H. SHORT, Primary Examiner E. WOODBERRY, Assistant Examiner U.S. Cl. X.R. 260--47 X, 463

Col.

Patent No.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION 3.641.200 D d February 8 1972 Inventor(s) er It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Col.

Col. 14,

Col. 14,

Col. 14, Mole".

Col. 14,

"m Mole".

Col. 14,

Col. 14, "5. 6 1."

Col. 16, "(mMole Col. 22,

"derived".

[SEAL] 2, line 43, after (e. g.

"lbers" should be "fibers".

5, line 63, "m. Mole-millimole" should be "m Mole-millimole.

6, line 42, "over" should be "over".

line 19, after "Also", "includede" should be "included" line 6, "mole" should be "m Mole".

line 11, "mole" should be "m Mole".

Table 1, after "COCl Slow" "(ml lole" should be "(m Table E, after "at the rate of 12.1", "mmole should be Table Y, after (mmole" should be "(m Mole".

Table V, under Third Column Heading, after "CH Cl should be "5. 6".

Table VII, after "Final rate of phosgene addition", should 5e "(m Mole".

line 55, after "groups are", "drived" should be A ttes t:

RUTH C. MASON Arresting Ofj'iver C. MARSHALL DANN Commissioner oflalents and Trademarks 

